Fabric and sheet material and the manufacture thereof



April 18, 1933.

c. DREYFUS ,960

FABRIC AND SHEET MATERIAL AND THE MANUFACTURE THEREOF Filed Dec. 15, 1925 MIXED FABRIC A/COTTON 8110C.

INVENTOR. CHHILLE Mmus ATTORNEYS l l l y Patented Apr. 18, 1933 pm'rao, STATES PATE Nr orrlca cAmLLa nan-nus, or Naw You, H. Y. I rAamc. Am) smear MATERIAL AND rm; MANUFACTURE 1' lication filed December 15, 1925, Serial no.

This invention concerns the manufacture of new fabrics or sheet materials having waterproof to gas-proof properties or capable of other applications. c

According to the invention, a fabric or sheet materlal is made byuniting under appropriate conditions of temperature and pressure, woven, 'tted or other fabric com- 9 posed of or containing filaments or fibers of thermoplastic cellulose derivative or derivatives with woven, knitted or other fabric composed of orcontaining filaments or fibers of non-thermoplastic or relatively non-thermoplastic material. :According to the invention woven, knitted "or other fabric made'of yarns composed of filaments or fibers of a thermoplastic cellulose derivative, such for example as cellulose acetate, ethyl-, methylor benzyl-cellulose,

nitro-cellulose or other esteror ether of cellu-- lose, or mixtures of such cellulose derivatives, is associated with woven, knitted, or other fabric made wholly or partly. of yarns composed of filaments or fibers of a non-thermoplastic -or relatively non-thermoplastic material, such for example as silk, cotton, linen, artificial filaments or fibers of the cellulose type, or wool or mixtures of any of such nonthermoplastic filaments-or fibers with each other or it may be with filaments or fibers of a thermoplastic cellulose derivative or derivatives, and the associated fabrics are subjected to heat and pressure, with or without employp thermoplastic cellulose derivative or deriva ment, assistance or application of plasticizing or softening agents or solvents of the tives; in this way the fabrics are united together and a compositesheet material 1s ob- 40 tained in which the pores or interstices are reduced to extremely minute dimensions, or closed completely, by the melting or softening efi'ect produced by the heat and pressure upon the filaments and fibers of the thermoplastic cellulose derivative or derivatives and by the uniting of the fabrics under the heat and pressure. 'lwvo of such fabrics, i. e. one of each of the two classes specified above, may be associated and united together as referred to,

or the respective fabrics may be disposed in any desired relative number in alternation 75,653, and in Great Britain January as. 1m.

with eachother. Thus for example a fabric of cotton or composed of or contaming other non-thermoplastic fiber may be disposed between two fabrics of cellulose acetate or other thermoplastic yarns; or a fabric of thermoplastic yarns may be disposed between two fabrics of cotton or composed of or containing other non-thermoplastic fibers; or four fabrics, two of each class, may be disposed so that the fabrics of thermoplastic yarn alternate respectively with the fabrics of cotton or composed of or containing other non-thermoplastic fibers, and so on.

The extent of the melting ,or softening ffect, degree of closin the pores or stices, and intimacy of union of the fabrics and therefore the degree of impermeability of the compound fabric or material produced, can vary with the degrees and duration of heat and pressure employed, and with whether plasticizers, or softeners or solvents are employed,and with thenumber of fabrics united together, or other circumstances.

Thus for example the heat and pressure (with or without employment or assistance of plasticizing or softening agents or solvents) may be such as to unite'the fabrics together and close or reduce to minute dimensions the pores\or interstices-of the compound or combined fabric and render the same water-resistingor even gas-resisting, without causing the filaments or fibers of the thermoplastic cellulose derivatives to dis appear. Or the heat and pressure may be such as to cause the filaments or fibers of thermoplastic cellulose derivatives to melt and disappear partly or entirely.

It is to be understood'that the degrees and duration of heat and pressure are interdependent and that all or-any of these condior longer is the more or less time to produce the effect in a more or less pronounced degree.

The degree of the melting effect, and the degree of intimacy of union of the compoe nent fabrics, may be increased or accentuated by the employment, assistance or application of plastieizin or softening ag'ents or solvents of the t ermo-plastic cellulose deriva- 8 tive or derivatives as-referred to, and it is to be understood that siich agents or solvents, ma be appliedto or incorporated in w er al of thecomponent fabrics before thei'ap plication of the" heat and pressure to the'associated fabrics, for example, by the application of such agents or solvents in solution in volatile solvents thereof that are.

not solvents of the cellulose derivative or derivatives, and that alternatively, such agents or solvents may be, incorporated in thefilaments or fibers (if-thermoplastic cellulose derivatives in the production thereof, for example by empkiying such agent 511 the spinning solutions om which. they are made.

Any lasticizin or softening agents or solvents, (prefera 1y high-boiling or relatively high-boiling), of the cellulose derivaene sulphonamide or its derivatives, diethylphthalate, paratoluene sulphonanilide, and high-boiling alkylated xylene sulphonamide derivatives or preparations (for example, monomethyl xylene sulphonamide).

As the meltingor softening efiect is increased or accentuated by the plasticizing or softening agents or solvents, one can employ less heat and/or pressure for the production of a given effect when such agents or solvents are employed.

The invention is particularly applicable when fabric of cellulose acetate yarns is used as the component thermoplastic fabric of the compound fabric or material, and will hereinafter be described inthis connection, it being understood, however, that fabrics of other cellulose esters or cellulose ethers may be employed as before indicated.

The heat and pressure may be applied in any appropriate way to the associated fabrics to be united together, for example by passage between pressure rollers, one or both of which is or are heated, or between a heated roller and a heated or cold plate or surface, or by pressure between heated plates or surfaces or between a heated plate or surface and a cold plate or surface, or by passing the associated fabrics under tension over a single heated roller, e. gLya calender roller, or by any other suitable means. In cases where the associated fabrics are passed through pairs of pressure rollers, the rollers in each pair may rotate at the same or at different speeds. Where the fabrics are passed under tension over a single heated roller, the roller may with advantage be rotated in an opposite direction to the travel of the fabric.

The manner in which the invention may tives'may be employed. 'As some instances there may be mentioned triacet1n, paratolube carried into effect can be illustrated by the following more detailed description, it being.

understood that this can-be varied widely without departing from the invention.

A woven or warp knitted fabric made of cellulose acetate am is associated with woven or knitted abric of silk, cotton, linen.

a given effect, or the same conditions of heat and pressure may be applied for.more or less time to produce the effect ina greater or less degree.

Thus for'example the associated fabrics (preferably with the cellulose acetate fabric treated with a plasticizing or softening agent or solvent) may be passed between heated pressure rollers, as in a calender, the conditions of heat, pressure and time being interdependent as before mentioned. For in temperatures between about and 180 C. under pressures of from about-300 to 600 lbs. or more per square inch, according to the degree of melting or softening effect on the yarns of the-cellulose acetate fabric and the degree of impermeability desired in the resulting compound material. The fabrics may be passed repeatedly between the heated rollers if desired, according to the degree of effect required.

Or again the associated fabrics may be passed once or repeatedly betweena heated roller and a cold roller or platen, or they may be pressed between heated plates or between a heated plate and a cold platen Or the heat and pressure may be applied in any other suitable way. t

- The application of plasticizingor softening agents or solvents of the cellulose acetate or other thermoplastic cellulose derivatives to assist the melting effect and the union of the component fabrics as hereinbefore referred to is especially of advantage where a high degree of impermeability to water is desired or for obtaining gas proof properties in the compound material. By way of example cellulose acetate fabric may be first treated with small quantities of water-insoluble, nonvolatile plasticizers, softeners or solvents of cellulose acetate before being associated with the other fabric for subjection to the heat and pressure." These quantities may vary stance the associated fabrics may be passed i slowly through heated calender rollers at for instancefrom about 1% to about.30% of the total quantity of cellulose acetate in the tate, or in any other convenient way. Any

' proof to with yarns of silk, cotton,

fabric, but more or less may be employed. The non-volatile plasticizers, softeners or solvents may be applied by spraying, dipping or otherwise, dissolved in a volatile solvent which does not dissolve the cellulose acesuitable plasticizers, softeners or solvents and any suitable volatile vehicle therefor may be used. As one example monomethylxylene sulphonamide may serve as a plasticizer and benzol as a vehicle, a suitable proportion being for instance about 20 grams of the sulphonamide dissolved in 100 grams of benzol for each 100 grams of cellulose .acetate fabric. When the volatile solvent of the plasticizer or softener evaporates, the plasticizer or softener remains distributed evenly on the cellulose acetate fabric so that when this is associated with the other fabric and subjected therewith to the heat and pressure, itassists the melting or softening effect on the cellulose acetate yarns and the union of the compone-nt fabrics and closing of the'pores or interstices of the component. fabrics, thereby producinga compound material havingwatergasproof properties according to the degree of dissolving or melting efi'ect etc, produced on the cellulose acetate by the con- .ditions of heat, pressure and time employed.

Instead of employing for association with fabric composed of filaments or fibers, fabric consisting wholly of yarns of silk, cotton or other non-thermoplastic fibers or filaments, one mayemploy for association therewith mixed fabric consisting of a mixture of thermoplastic yarns linen, artificial silk of the cellulose type, wool or other non-thermoplastic fibers or filaments, or consisting of or comprising yarns composedof a mixture of thermoplastic filaments or fibers with nonthermoplastic fibers or filaments. Or one may even, though with less advantage, employ only such mixed fabrics for making the compound material under the effect of heat and pressure, with or without .application of plasticizing or softening agents or solvents, the heat. and pressure causing more or less melting or softening of the thermoplastic yarns, filaments or fibers and uniting the component fabrics together to form a compound material possessing greater or less degrees of resistance to penetration by water or even' gases, according to the temperature, pressure and duration of pressure or other conditions.

While fabrics made with yarns or fibers of nitrocellulose filaments or fibers may be employed in practising the invention this is less advantageous owing to the inflammability of nitrocellulose.

The compound materials made according to the invention. may be employed more particularly for applications where resist- '1n drawing.

this drawing Figure 1 shows the-fabric yarns of thermoplastic v rials for garments, coverings, etc. oras materials for airships or othergas containers, but materials made accordingto the invention may be employed for any other technical orindustrial applications.

For a further understanding of my invention reference is made to the accompany- 1 consisting wholly. of yarns of a thermoplastic derivative. of cellulose superposed upon the fabric 2 consisting of cotton yarns. After the two fabrics are pressed at elevated temperature in accordance with my invention, a sheet such as shown in Figure 2 is formed, wherein amore or less impervious layer la'of the thermoplastic derivative adheres to the cotton fabric 211.

In Figure 3 there are shown three layers of fabric, the middle fabric consisting of yarns of a thermoplastic derivative of cellulose such as cellulose acetate. In this figure a cotton fabric 3 is placed on the fabric 4 made of cellulose acetate yarns which in turn such as shown in Figure 4 is formed, wherein the intermediate layer 4a is a more or less impervious sheet of cellulose actetate between the cotton fabrics 3a and 5a. 1

In Figure 5 there are shown three layers of fabric in which the middle one is cotton; while the outer fabrics are made of a thermoplastic derivative of cellulose yarn. The fabrics made of cellulose acetate are indicated at 6 and 8- While the cottonfabric is indicated at 7 After pressing these layers in accordance with my invention, a product .shown in Figure 6 is produced wherein the cotton fabric 7 a has an upper layer 6a and a lower. layer 811 of more or less impervious cellulose acetate thereon..-.

In Figure 7 is shown a fabric 9 having yarns of cotton and also yarns of thermoplastic derivative of cellulose superposed upon a fabric 10 consisting wholly of silk yarns. After pressing in accordance with my invention a material shown in Figure 8 is formed wherein the silk fabric 10a has thereon a more or less impervious sheet 9a which has cotton yarns imbedded therein.

In Figure 9 there is shown a plan view of a mixed fabric containing yarns 12 of a thermoplastic derivative of cellulose such as cellulose' acetate and yarns 11 of cotton. This sort of fabric may be used as the fabric 9 in Figure 7, or it may be pressed alone in ac cordance with my invention to form a more or less impervious film or thermoplastic derivative of cellulose in which cotton yarns are imbedded.

Having now particularly described and ascertained the nature of my said invention and in what manner the same is to be; performed, I- declare that what I claim is:-

1. A recess for the manufacture of 'composite s eet material which comprises applying to a fabric containing yarns comprising a thermoplasticderivative of cellulose a softening agent in solution in volatile solvents which are non-solvents of said derivative, associating it with another fabric by superposition, and subjecting the fabrics to heat and pressure to soften' the cellulose derivative and unite the fabrics to form a f sheet material of increased impermeability. 2. A composite sheet material comprising a plurality of fabrics, at least one of which contains yarns comprising a thermoplastic derivative of cellulose, which fabrics have been united into a single sheet of relatively 2 increased .impermeability by the application of heat and pressure. J

3: A process for the manufacture of composite sheet material which comprises applying to a fabric containing yarns com- 2 prising cellulose acetate a softeningagent in solution in volatile solvents which are nonsolvents of said cellulose acetate, associatin it with another fabric by superposition, an

subjecting the fabrics to heat and pressureto soften the cellulose acetate and unite the fabrics to forma sheet material of increased impermeability.

4. A composite sheet material comprising a plurality of fabrics at least one of which contains yarns comprising cellulose acetate which fabricshave been united into a single sheet of relatively increased impermeability by the application of heat and pressure.

In testimony whereof, I have hereunto subscribed my name;

OAMILLE DREYFUS. 

